Engine Cooling System: Removal & Installation Toyota Highlander I рестайлинг

REPLACEMENT

HINT

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.

1. DRAIN ENGINE COOLANT (See «COOLANT (2AZ-FE)»(ref-226412-S07429961942006032800000) )
2. DISCONNECT RADIATOR RESERVE TANK HOSE OR PIPE
3. DISCONNECT RADIATOR HOSE INLET
4. DISCONNECT RADIATOR HOSE OUTLET
5. DISCONNECT OIL COOLER OUTLET HOSE NO.2
6. DISCONNECT OIL COOLER OUTLET HOSE NO.3
7. REMOVE RADIATOR SUPPORT UPPER Remove the radiator support upper with the 2 bolts.
8. REMOVE RADIATOR ASSY Disconnect the fan motor connector. Remove the radiator from the body.
9. REMOVE RADIATOR SUPPORT LOWER
10. REMOVE FAN ASSY W/MOTOR Remove the 6 bolts and fan from the radiator.
11. INSTALL FAN ASSY W/MOTOR Install the fan to the radiator with the 6 bolts. Torque: 7.8 Nm (80 kgfcm, 69 in. lbf)
12. INSTALL RADIATOR ASSY Install the radiator to the body. Connect the fan motor connector.
13. INSTALL RADIATOR SUPPORT UPPER Install the radiator support upper with the 2 bolts. Torque: 12.8 Nm (130 kgfcm, 9.4 ft lbf)
14. ADD ENGINE COOLANT (See «COOLANT (2AZ-FE)»(ref-226412-S07429961942006032800000) )
15. CHECK FOR ENGINE COOLANT LEAKS (See «COOLING SYSTEM (2AZ-FE)»(ref-226412-S29116418352006032800000) )

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. REMOVE DRAIN PLUG Remove the drain plug. Remove the O-ring.
2. ASSEMBLE SST SST 09230-01010 Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 In.) NOTE: If the stopper bolt is not adjusted, the claw may be damaged.
3. UNCAULK LOCK PLATE Using SST, grip the handle until stopped by the stopper bolt to uncaulk the lock plate. SST 09230-01010 (09231-01010, 09231-01030)
4. REMOVE RADIATOR TANK UPPER AND TANK LOWER Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic-faced hammer, and remove the tank. Remove the O-ring.
5. REMOVE OIL COOLER ASSY Remove the cooler pipe Loosen the 2 nuts and 2 plate washers. Remove the oil cooler. Remove the 2 O-rings from the oil cooler.
6. INSTALL OIL COOLER ASSY Clean the O-ring contact surfaces of the lower tank and oil cooler. Install 2 new O-rings to the oil cooler. Install the oil cooler to the lower tank with the 2 plate washers and nuts. Torque: 8.34 Nm (85 kgf.cm, 74 In.lbf) Install the cooler pipe in the direction indicated by the arrows in the illustration. Torque: 14.71 N.m (150 kgf.cm, 11 ft lbf)
7. INSPECT LOCK PLATE FOR DAMAGE HINT: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary. NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
8. INSTALL RADIATOR TANK UPPER AND TANK LOWER After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it. Install the tank without damaging the O-ring. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.
9. ASSEMBLE SST SST 09230-01010,09231-14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension: 8.4 mm (0.331 in.)
10. CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230-01010 HINT: Do not tap the areas protruding around the pipes, brackets or tank ribs. The points shown in the illustration and oil cooler near here (A/T) cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. Check the lock plate height (H) after completing the caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle and caulk it again.
11. INSTALL DRAIN PLUG Install a new O-ring to the drain plug. Install the drain plug.
12. INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm 2 ,26 psi) Submerge the radiator in water. Inspect for leaks. HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water Before doing the water leak test, first swish the radiator in water until all air bubbles disappear.

Scheme 46

1. INSPECT COOLING SYSTEM FOR LEAKS Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. Fill the radiator with coolant and attach a radiator cap tester. Warm up the engine. Using a radiator cap tester, increase the pressure inside the radiator to 118kPa(1.2kgf/cm 2 ,17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR The engine coolant level should be between the "LOW" and "FULL" lines when the engine is cold. If low, check for leaks and add "Toyota Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the "FULL" line. Do not use plain water alone.
3. CHECK ENGINE COOLANT QUALITY Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole. Also, the coolant should be free from oil. If excessively dirty, replace the coolant. Reinstall the radiator cap.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. INSPECT THERMOSTAT HINT: The valve opening temperature is stamped on the thermostat. Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat is at low temperatures (below 77°C (171°F)). If not closed, replace the thermostat.
2. INSPECT RADIATOR CAP SUB-ASSY NOTE: If the reservoir cap has contaminations, always rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. When performing steps (a) and (b) below, keep the tester at an angle of over 30° above the horizontal. Using a radiator cap tester, slowly pump the tester and check that air is being released from the vacuum valve. Pump speed: 1 push every 3 seconds or more NOTE: Push the pump at a constant speed. If air is not being released from the vacuum valve, replace the reservoir cap. Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTE: The specified pump speed should be followed for the first pump only. It will close the vacuum valve. Once the vacuum valve is closed, the pump speed can be reduced. Standard opening pressure: 93 to 122 kPa (0.95 to 1.25 kgf/cm 2 , 13.4 to 17.6 psi) Minimum opening pressure: 78 kPa (0.8 kgf/cm 2 , 11.4 psi) HINT: Use the tester's maximum reading as the opening pressure. If the maximum reading is less than the minimum opening pressure, replace the radiator cap.

HINT

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.

Scheme 51

1. DRAIN ENGINE COOLANT (See «COOLANT (3MZ-FE)»(ref-226412-S16627119532006032800000) )
2. REMOVE RADIATOR HOSE OUTLET
3. REMOVE WATER INLET PIPE Remove the bolt and inlet pipe.
4. REMOVE WATER INLET Remove the 3 bolts and water inlet.
5. REMOVE THERMOSTAT
6. INSTALL THERMOSTAT Install a new gasket to the thermostat. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat into the water inlet housing. HINT: The jiggle valve may be set within 15° of either side of the prescribed position.
7. INSTALL WATER INLET Torque: 8.0 N m (82 kgf cm, 71 in. Ibf)
8. INSTALL WATER INLET PIPE Install a new O-ring to the inlet pipe. Apply soapy water to the O-ring. Connect the inlet pipe to the water inlet. Install the bolt holding the inlet pipe to the cylinder head. Torque: 20 N m (204 kgf cm, 15 ft Ibf)
9. ADD ENGINE COOLANT (See «COOLANT (3MZ-FE)»(ref-226412-S16627119532006032800000) )
10. CHECK FOR ENGINE COOLANT LEAKS (See «COOLING SYSTEM (2AZ-FE)»(ref-226412-S36470855222006032800000) )

Scheme 52

1. INSPECT FINS BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTE: If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard: STEAM CLEANER PRESSURES Distance Steam Cleaner Pressures 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kgf/cm 2 , 427 to 711 psi) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kgf/cm 2 , 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components.

Scheme 53

Scheme 54

HINT

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.

1. DRAIN ENGINE COOLANT (See «COOLANT (3MZ-FE)»(ref-226412-S16627119532006032800000) )
2. DISCONNECT RADIATOR RESERVE TANK HOSE OR PIPE
3. DISCONNECT RADIATOR HOSE INLET
4. DISCONNECT RADIATOR HOSE OUTLET
5. DISCONNECT OIL COOLER OUTLET HOSE NO. 2
6. DISCONNECT OIL COOLER OUTLET HOSE NO. 3
7. REMOVE RADIATOR SUPPORT UPPER Remove the radiator support upper with the 2 bolts.
8. REMOVE RADIATOR ASSY Disconnect the fan motor connector. Disconnect the ECT switch No. 1 connector. Remove the radiator from the body.
9. REMOVE RADIATOR SUPPORT LOWER
10. REMOVE FAN ASSY W/MOTOR Remove the 6 bolts and fan from the radiator.
11. INSTALL FAN ASSY W/MOTOR Install the fan w/ the radiator with the 6 bolts. Torque: 7.8 Nm (80 kgf cm, 69 in.lbf)
12. INSTALL RADIATOR ASSY Install the radiator to the body. Connect the ECT switch No. 1 connector. Connect the fan motor connector.
13. INSTALL RADIATOR SUPPORT UPPER Install the radiator support upper with the 2 bolts. Torque: 12.8 Nm (130 kgf cm, 9 ft lbf)
14. ADD ENGINE COOLANT (See «COOLANT (3MZ-FE)»(ref-226412-S16627119532006032800000) )
15. CHECK FOR ENGINE COOLANT LEAKS (See «COOLING SYSTEM (2AZ-FE)»(ref-226412-S36470855222006032800000) )

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. REMOVE DRAIN PLUG Remove the drain plug. Remove the O-ring.
2. ASSEMBLE SST SST 09230-01010 Install the claw to the overhaul handle, inserting it into the hole in part A as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTE: If the stopper bolt is not adjusted, the claw may be damaged.
3. UNCAULK LOCK PLATE Using SST to release the caulking, grip the handle until stopped by the stopper polite uncaulk the lock plate. SST 09230-01010 (09231-01010,09231-01030)
4. REMOVE RADIATOR TANK UPPER AND TANK LOWER Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic-faced hammer and remove the tank. Remove the O-ring.
5. REMOVE OIL COOLER ASSY Remove the cooler pipe Loosen the 2 nuts and 2 plate washers. Remove the oil cooler Remove the 2 O-rings from the oil cooler.
6. INSTALL OIL COOLER ASSY Clean the O-ring contact surface of the lower tank and oil cooler. Install 2 new O-rings to the oil cooler. Install the oil cooler to the lower tank. Install the plate washer and nut. Torque: 8.34 Nm (85 kgf.cm, 74 in.lbf) Install the pipe. Torque: 14.71 Nm (150 kgf.cm, 11 ft lbf)
7. INSPECT LOCK PLATE FOR DAMAGE Inspect the lock plate for damage. HINT: If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary. NOTE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.
8. INSTALL RADIATOR TANK UPPER AND TANK LOWER After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it. Install the tank without damaging the O-ring. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.
9. ASSEMBLE SST SST 09230-01010,09231-14010 Install the punch assembly to the overhaul handle, inserting it into the hole in part A as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 8.4 mm (0.331 in.)
10. CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230-01010 HINT: Do not tap the areas protruding around the pipes, brackets or tank ribs. The points shown in the illustration and oil cooler near here (A/T) cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. Check the lock plate height (H) after completing the caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again.
11. INSTALL DRAIN PLUG Install a new O-ring to the drain plug. Install the drain plug.
12. INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm 2 , 26 psl) Submerge the radiator in water. Inspect for leaks. HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator in water until all air bubbles disappear.